Picture of CrossFit Style Plyo Box (ShopBot!)

This is my second attempt at a plyo box. This time in technicolor! I took a ShopBot class at TechShop and decided it would work better than the inaccuracies of the table saw and band saw.


3/4" sheet of plywood (I chose a birch variety)

Two-flute end mill (I chose 1/4")


Screws (at least 1.5 in long)



End Mill

Drill bit (1/8")

Brass screws (long enough to go through material; 1.5")

Step 1: Creation of the plans

Picture of Creation of the plans
plyo box.png

I detailed in my other instructable that I modified a few plans to get to one I liked. I mocked up the same plans in Illustrator which is the one of the pictures in this step. I was able to include the drill holes here as well. I planned on using the edges to my advantage to minimize cuts, this wasn't the best choice and I will tell you why later in the next step.

Here is the file that I put together with Adobe Illustrator. It is in a public file from dropbox.



If you use a 3/4 in veneer and a few 1x2's or 2x2's it should be more than enough. Just frame the inside and a brace in the middle of each piece. You can actual use this for three different heights if you reinforce it right.

chrisgrames (author)  CoastalDrifter7 months ago
I really feel it is strong enough without any bracing inside already. Certainly it's strong enough in the narrow directions, and the widest (24" tall) which is what use the most, I feel comfortable without any bracing. Of course, better safe than sorry.

Thanks for the directions, is the plyo box strong enough on it's own for someone 220lbs? Or should it be reinforced with 2x4s?

chrisgrames (author)  denisemoore1 year ago
I wouldn't be able to give you an answer confidently since I am not 220lbs or an engineer. While the box feels sturdy to me, the boxes that get sold by gyms and equipment manufacturers almost always have a center piece internally for reinforcement.